U.S. patent application number 11/848074 was filed with the patent office on 2009-03-05 for system for displaying and monitoring practical data in controllers.
Invention is credited to Goran Igic, Thomas A. Moulton, David R. Walker, David A. White.
Application Number | 20090064026 11/848074 |
Document ID | / |
Family ID | 40409468 |
Filed Date | 2009-03-05 |
United States Patent
Application |
20090064026 |
Kind Code |
A1 |
Walker; David R. ; et
al. |
March 5, 2009 |
System for Displaying and Monitoring Practical Data in
Controllers
Abstract
A device that provides for the non-invasive data monitoring of
analog IO of a Programmable Logic Controller (PLC) system. The
output is ultimately displayed on an interface in real-time and is
measured directly from the IO channel. This type of device allows
the accurate reading and analysis of errors and erroneous data
within a device and transmission of said data to disparate
secondary devices for use.
Inventors: |
Walker; David R.; (New Port
Richey, FL) ; Igic; Goran; (New Port Richey, FL)
; Moulton; Thomas A.; (New Port Richey, FL) ;
White; David A.; (New Port Richey, FL) |
Correspondence
Address: |
GREENBERG & LIEBERMAN, LLC
2141 WISCONSIN AVE, N.W., SUITE C-2
WASHINGTON
DC
20007
US
|
Family ID: |
40409468 |
Appl. No.: |
11/848074 |
Filed: |
August 30, 2007 |
Current U.S.
Class: |
715/772 ;
710/1 |
Current CPC
Class: |
G05B 19/058 20130101;
G05B 2219/14073 20130101; G05B 2219/14008 20130101 |
Class at
Publication: |
715/772 ;
710/1 |
International
Class: |
G06F 3/048 20060101
G06F003/048; G06F 3/01 20060101 G06F003/01 |
Claims
1. A system for displaying and monitoring practical data in
controllers, comprising: a display interface; and an I/O card, in
communication with said display interface.
2. The system of claim 1, wherein said display interface is
configured to monitor data output in a non-invasive fashion.
3. The system of claim 1, wherein said display interface is
configured to monitor data analog input data.
4. The system of claim 1, wherein said display interface is
configured to monitor output data.
5. The system of claim 1, wherein said display interface is
configured to monitor a programmable logic controller.
6. The system of claim 1, wherein said display interface and said
I/O card are in direct communication with one another.
7. The system of claim 1, wherein said I/O card is connected to
multiple sensors.
8. The system of claim 6, wherein said I/O card is connected to
multiple sensors.
9. The system of claim 1, wherein said display interface is
configured to receive data in real time.
10. The system of claim 6, wherein said display interface is
configured to receive data in real time.
11. The system of claim 10, wherein said display interface is
configured to compile and store said data.
12. The system of claim 10, wherein said display interface in
configured to communicate with a front side bus.
13. The system of claim 10, wherein said display interface is
configured with flash memory.
14. The system of claim 10, wherein said display interface is
configured with static memory.
15. The system of claim 11, wherein said data is viewable as
digital data counts as well as in engineering units.
16. The system of claim 11, wherein said display interface is
configured to allow multiple channels to be viewed
simultaneously.
17. The system of claim 11, wherein said display interface is
configured to allow a data channel, being viewed, to be changed
with the press of a single button.
18. The system of claim 17, wherein said single button is
configured to manipulate said display interface by holding down
said single button or releasing said single button at the
appropriate intervals to allow a user to view data required.
19. The system of claim 6, wherein said display interface and said
I/O card are in direct communication with one another
non-invasively.
20. A system for displaying and monitoring practical data in
controllers, comprising: a monitoring device; a programmable logic
controller, in communication with said monitoring device; a
real-time and direct interface between in and out leads of data
channels from multiple sensors in said programmable logic
controller; wherein said monitoring device is in direct
communication with said programmable logic controller; and wherein
said monitoring device has a display, a central processing unit, a
front side bus, a data storage means allowing data to be viewed by
a user in digital data counts and engineering units of said data
channels simultaneously and manipulated through the use of a single
button press.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a device that provides for
the non-invasive data monitoring of analog IO of a Programmable
Logic Controller (PLC) system. The output is ultimately displayed
on the display interface in real-time and is measured directly from
the IO channel.
BACKGROUND OF THE INVENTION
[0002] PLCs are important and necessary elements when working with
automated industrial processes. A major driving force in industry
and thus the economy as a whole rests with industrial output. The
front line of industry can then be regarded as the factories, where
automated systems help mass-produce numerous products on assembly
lines and other like systems. In order to accomplish industrial
goals, it is crucial that the automation is controlled properly.
Making this even more important is the fact that factories often
feature dusty and extreme temperature conditions that can interfere
with computers and other systems.
[0003] At the heart of this automation is the PLC. The general PLC
is designed to withstand such conditions inside the factory in
order to create a more effective automated environment. The PLCs
function is to utilize hardware and software capabilities to
basically control the automated process. A central processing unit
(CPU) generally interfaces with an input/output system (I/O module)
to ultimately engage the controlling process through the additional
use of sensors, switches and other devices. The output of this
interaction within the PLC is crucial as timing, voltage, current
and other factors must be at specification to properly control the
automation process. Basically, if an output result is not responded
to in a certain amount of time, the control will be off and thus
will cause the entire overall automation process to be off and not
in proper control.
[0004] In addition, analog I/O modules are vitally important to
industry as these elements of the PLCs are relied upon to measure
dimensions and other such significant elements as motion, pressure
and temperature. In this regard, there is a significant need for a
monitoring system that can directly and easily monitor the units of
voltage and other factors. In its most basic sense, this type of
monitoring is used to ensure that everything is working
properly.
[0005] Currently, most designs require meters or additional
computer connections to determine whether the controller and
consequently the entire automation is running properly. These
meters and additional computers employ a process where the PLC
output gleaned from the sensors and I/O modules read the output for
an item such as voltage. However, the meter and additional computer
approaches require costly and invasive methods that delay the
overall monitoring process. In addition, the meter and additional
computer approach often require that parts be taken out of the
overall component and transferred to the external monitoring
device. This creates more issues as it can affect the quality of
this vital reading. For example, a meter used to decipher digital
output can actually cause a reading to change when placed near the
circuits. Even a slight change in the reading can cause costly
problems for the overall automation. It should be noted that
removing covers and moving cables could affect monitoring. Current
display methods involve this type of invasive activity, which
perpetuates inherent issues of skewed data. Because of these
factors, there is a substantial need for a display and monitoring
method that is non-invasive. By satisfying this need of a
non-invasive monitoring method such as is the case with the present
invention, controllers and industrial automation in general will
greatly benefit from this added safeguard related to the fact that
a user can simply read the data without adversely affecting with
vital elements of the control system.
[0006] Recognizing the importance of constant monitoring, some have
incorporated attempts at providing better monitoring devices to the
analog I/O modules. For example, light-emitting diodes (LED) have
been attached that illuminate as an alarm system when something
such as voltage output is outside a desired range. However, this
alarm system merely issues an alert and does not eliminate the
typical requirement to intervene with the functionality of the PLC
in order to establish a meter or additional computer for an output
reading.
[0007] Currently, there is no way for a person in real-time to
physically view an analog I/O module and determine exactly what is
being sent to the CPU of the PLC. Thus, there is a need for a
device that contains a LCD-type element that actively displays what
has been converted and sent to the CPU in real-time. This need is
substantial because a device such as the present invention will
allow a person to see the exact condition of the analog I/O module
at any given time. This then will eliminate all the extraneous
steps that are currently undertaken. This need is established with
the present invention because a user can use the present invention
to view the digital data in counts, as well as in engineering
units. By satisfying this need, automated industry will
significantly benefit through the much more cost-effective and
increased monitoring of the analog I/O module output.
[0008] U.S. Pat. No. 5,640,099 issued to Sanada on Jun. 17, 1997,
is a method and apparatus for detecting a short circuit point
between wiring points of a device. Unlike the present invention,
Sanada employs costly elements such as laser beams to merely detect
deficiencies and does not convert conditions such as voltage and
temperature into digital data.
[0009] U.S. Pat. No. 5,058,052, issued to Sexton et al on Oct. 15,
1991, is a method for checking for errors in a PLC based on a
predetermined list of possible deficiencies to be concerned about.
When a deficiency is discovered, an error alert commences to inform
a user that there may be a problem with the control. Unlike the
present invention, Sexton is a relatively costly endeavor in that
it integrates merely an alert mechanism to inform a user of a
deficiency. The user must then take additional and invasive steps
to determine the exact issue with the PLC instead of having the
opportunity to quickly read a real-time display to determine the
exact deficiency, as is the case with the present invention.
[0010] There is a distinct need to quickly and accurately detect
output deficiencies in PLCs due to the strict timing and often
rough conditions associated with the control of automated
industrial elements. While alert methods certainly have the ability
to let a user know of a problem, the fact remains that the problem
either has already occurred or time must be taken to determine what
exactly the problem is. A related issue to these alert methods is
that they become costly in both additional material and time as an
investigation of the potential deficiency is investigated. Thus,
there is a need for a non-invasive device that can always be
available to convert and send voltage or current signal into
digital data counts or engineering units to the CPU and display
them in real-time.
[0011] The present invention satisfies that need and is significant
in that it provides a cost-effective and practical method for
quickly monitoring the progress of the controller output relating
to an analog I/O module. At the same time, the present invention
also is unique in the fact that it allows a user to monitor data
without having to potentially compromise the results--even just a
tiny bit--because of the non-invasive method of display.
[0012] Moreover, the present invention allows for the proper
verification of a system at any time and in real-time without the
invasive need for fiddling with internal parts or cables. At the
same time, most other PLC displays rely on intermediate elements
throughout the system to complement the function relating to the
invasive methods of monitoring. Beyond the typical invasive
problems, these intermediate systems sometimes interfere with the
regular flow and process of the data. This problem sometimes leads
to the corruption of data. The present invention, however, solves
this problem by directly connecting the I/O card to the display
interface. This essentially cuts out the negative effects of these
intermediate elements while also sparing the monitoring system of
potentially data-skewing invasive procedures. For these reasons,
there is a substantial need for the present invention.
SUMMARY OF THE INVENTION
[0013] The present invention is a non-invasive method that permits
a user to monitor vital information relating to a PLC by viewing a
display interface. The display interface is directly connected to
an I/O card. This distinction over other relevant inventions is
crucial because the present invention does not alter any system to
which it is connected whatsoever; whereas other monitoring
inventions actually affect the system to which they are connected,
modifying such systems or changing system data. In other
inventions, the analysis/monitoring device can have its own errors,
making analysis of a problem in the system difficult at best. In
the present invention, there is a direct interface to each section
of the system to which it is connected, and as such the user only
is looking at true data from the system that is not marred by any
errors of the present invention.
[0014] This vital information includes voltage input/output,
current input/output, pressure and temperature. These elements of
the automation process are detected via sensors built into the
overall system. The analog I/O module of the PLC, meanwhile,
converts the output gleaned from these sensors into a digital value
as it sends the information to the CPU. The present invention is
non-invasive so that it can easily be used without having to delve
deeper into the PLC system. Instead, the data is compiled in
real-time and transferred via the I/O card to the display
interface. The user may then scroll through various menu options to
determine and ultimately view desired data.
[0015] The present invention is a method that employs a display
interface, preferably but not limited to LCD, to actively and in
real-time display exact information of what has been converted from
the I/O card and sent to the CPU. In this manner, a user can
instantly learn what the analog I/O module is doing at any given
moment. This allows for instant reaction if the user needs to
correct a potential deficiency.
[0016] The LCD of the present invention displays the value of the
specific unit of measure being used at any given moment. This
allows for the user to see digital data counts as well as
engineering units such as volts, milliamps and temperature.
[0017] In an embodiment of the present invention, only one button
is needed to view the relevant data. In addition, the LCD of the
present invention permits the user to view multiple channels at one
time. These elements of the present invention result in a
cost-effective method of instant knowledge relating to the analog
I/O output.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] FIG. 1 is a front view of the display interface (20) of the
present invention.
[0019] FIG. 2 is a top view of the display interface (20) of the
present invention
[0020] FIG. 3 is a flow chart of the workings related to the
display interface (20) of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] FIG. 1 gives us a view of the display interface (20), as it
is located on the panel display casing (10). The display interface
(20) as seen in FIG. 1 serves to display text in real-time. This
text displays everything ranging from the initial self-test upon
powering up to fault messages. Beyond those functions, the display
interface (20) provides real-time numbers and text so that the user
can instantly learn various conditions of the PLC. For example, a
user monitoring the display interface (20) can view and instantly
comprehend the data moving to the CPU because it also appears on
the display interface (20) in engineering terms and/or relevant
data counts. This means that a user may simply read the output
emanating from the PLC where he or she can quickly deduce exactly
what is going on with the output and consequently, with the entire
automation operation.
[0022] In addition, FIG. 1 shows that the display interface (20) is
protected and surrounded by a panel display casing (10). There is
no need to make invasive movements into the panel display casing
(10) because all data is may be automatically displayed in
real-time on the display interface (20). Moreover, one aspect that
minimizes cost and complexity in regard to the present invention is
the panel button (30). Only one panel button (30) is necessary for
a user to navigate the varying areas of relevant interest in regard
to what is read on the display interface (20). After powering up
the overall device, the panel button (30) can function as the sole
navigational tool for the display interface (20).
[0023] For example, if a user wants to view data in voltage units,
the user would click and hold down the panel button (30) as the
display interface (20) scrolls through various primary menu items
such as setup and display. Once the user reaches a menu item that
he or she would like to move forward with, the user simply releases
the panel button (30). Once the panel button (30) is released by
the user, the display interface (20) displays secondary screens
serving as sub-displays to the primary menu item that was selected
by releasing the panel button (30). If the user wishes to view data
in voltage units, then he or she would release the panel button
(30) from the primary menu scroll on the
"display"--"units"--"+/-V"--"mA, V." By releasing the panel button
(30) at this point, the display interface (20) will allow the user
to view the secondary display screen where the user will press the
panel button (30) each time he or she wishes to scroll to a new
secondary display item. Ultimately, in the example above, the user
will press and release the panel button (30) until the relevant
voltage units are being displayed in real-time. It is the ability
of the panel button (30) to effectively navigate through the
various menus and text options of the LCD panel display (20) that
saves space and becomes more efficient.
[0024] In FIG. 2, we see a top view of the present invention in
terms of placement of the panel display casing (10) in relation to
the PLC casing (50). The display interface (20) is directly
connected to the I/O card (60) through conventional means. The
reason the display interface (20) is in direct communication with
the I/O card (60) is to eliminate the need for intermediate
elements that can potentially corrupt data. Instead, data flows
directly from the I/O card (60) to the display interface (20).
[0025] As we see in FIG. 2, wire connections (40) provide proper
data conduits between the display interface (20) and the I/O card
(60) of the PLC. These wire connections (40) are connected at a
conventional connection point (70) as shown in FIG. 2. Data
transferred through the wire connections (40) to the display
interface (20) via the conventional circuit board (70) work
together to provide the real-time data in their respective units of
the present invention.
[0026] In FIG. 3, we see a flow chart describing an embodiment of
the present invention in terms of an example of how a user may
scroll through an embodiment of the display interface (20) and view
various elements. It is important to note that other display
elements leading a user to ultimately view data in engineering
units or other digital value may also be displayed in the display
interface (20), and the flow chart in FIG. 3 is merely an example
of an embodiment of this element.
[0027] The first item a user may view after the present invention
is powered on is a screen stating the text, "passed self test"
(100). The self test is an automatic function after initial
powering up to confirm that all systems of the PLC and display
interface (20) of the present invention are functioning as
expected. After confirmation of "passed self test (100)," the user
may hold down the panel button (30) as described in FIG. 1. When
the user holds down the panel button (30), he or she will be able
to cycle through the primary screens of the present invention. In
order of this embodiment of the present invention if the user
scrolls all the way through, he or she will see "display setup
info" (110), "display status info" (120), "display units decimal
counts" (130), "display units hex counts" (140) and "display
units+/-V, mA, V" (150).
[0028] The "display status info" (120) screen may lead a user to an
informational screen declaring an "end of status menu list" (190).
The process of leading users to the secondary displays is as
described in FIG. 1 in regard to holding the panel button (30) down
until the scroll reaches the desired point. When that happens, the
user may release the panel button (30) and that particular screen
will have been selected, thus leading the user to a secondary
display. For example, the "display units decimal counts" (130) as
seen in FIG. 3 may lead a user to a secondary display featuring
units in decimal counts (200). The "display units hex counts" (140)
will lead a user to a secondary display showing units in hex counts
(210). The "display units+/-V, mA, V" (150) may lead a user to a
secondary display featuring voltage and mA units (220).
[0029] The "display setup info" (110) will lead a user to a set of
auto-cycling screens that will permit the user to view various
screens to display information relating to the setup and
propagation of the present invention. In FIG. 3, we see that the
"display setup info" (110) may lead a user to a forward reverse
screen (160), voltage and milliamp screen (170) and a channel
enabler screen (180) Once the auto-scanning process completes
itself in these screens, a user will again be able to view the
process from the beginning.
[0030] An additional embodiment of the present invention as seen in
FIG. 3 revolves around the display of error messages. An embodiment
of the present invention will insert error messaging to be viewed
in the display interface (20) if there is a deficiency in the PLC
or overall data conversion and display process. In one embodiment
of the present invention, a view will be notified on the display
interface (20) whether there is a missing external 24 VDC element
(230), self test fail, replace module (240) or missing
configuration data (250). Since there may be multiple errors, the
conclusion of the error screens scroll will display a message
stating an "end of status menu list" (260). From there, the user
may scroll back to the beginning of the error thread. In addition,
a fault message screen (270) may appear in place of data in the
event of a problematic condition. For example, an embodiment of the
present invention can declare that an input signal is "over" the
maximum detectable by the module or "under", meaning the voltage or
current input signal is at 0. An "open" message may indicate that
the input signal is less than a specified current level. A "spare"
message may indicate that an input is not being used. Other
alternative methods for the implementation of this concept include,
but are not limited to (a) the use of an infrared (IrDA) to a
handheld display thereby allowing the read device to be physically
separate from the device itself, (b) the use of bluetooth or other
wireless to display device(s) thereby allowing even greater range
for the information to travel; (c) optical projection to
translucent screen or retinal viewer(s) as an alternative display
method; and (d) compact LCD or other micro-display to be read and
displayed with Barcode like scanner if one wants to minimize the
weight or size of the device.
[0031] The present invention should be understood to be, in a
preferred embodiment, a system for displaying and monitoring
practical data in controllers, comprising a display interface; and
an I/O card, in communication with said display interface.
Furthermore, said display interface is configured to monitor data
output in a non-invasive fashion. Also, said display interface is
configured to monitor data analog input data. Moreover, said
display interface is configured to monitor output data.
Additionally, said display interface is configured to monitor a
programmable logic controller. Also, said display interface and
said I/O card are in direct communication with one another.
Further, said I/O card is connected to multiple sensors.
Additionally, said display interface is configured to receive data
in real time. Also, said display interface is configured to receive
data in real time. Moreover, said display interface is configured
to compile and store said data. Further, said display interface in
configured to communicate with a front side bus. Also, said display
interface is configured with flash memory. More still, said display
interface is configured with static memory. Even further, said data
is viewable as digital data counts as well as in engineering units.
Additionally, said display interface is configured to allow
multiple channels to be viewed simultaneously. Also, said display
interface is configured to allow a data channel, being viewed, to
be changed with the press of a single button. Further, said single
button is configured to manipulate said display interface by
holding down said single button or releasing said single button at
the appropriate intervals to allow a user to view data required.
Also, said display interface and said I/O card are in direct
communication with one another non-invasively.
[0032] In another embodiment of the present invention, the present
invention is a monitoring device; a programmable logic controller,
in communication with said monitoring device; a real-time and
direct interface between in and out leads of data channels from
multiple sensors in said programmable logic controller; wherein
said monitoring device is in direct communication with said
programmable logic controller; and wherein said monitoring device
has a display, a central processing unit, a front side bus, a data
storage means allowing data to be viewed by a user in digital data
counts and engineering units of said data channels simultaneously
and manipulated through the use of a single button press.
[0033] The present invention can also have a remote interface that
has analysis programming which automatically alerts a human (via a
connection to a telephone or an instant message client) if certain
preset parameters are met.
[0034] It should be noted that all methods of connections and
interfaces are conventional to one skilled in the art. If not
specifically mentioned, any and all connections and interfaces done
via any and all conventional means appropriate to one skilled in
the art.
[0035] It should be understood that the present invention is not
solely limited to the embodiments described above, but is any and
all of the embodiments within the scope of the following
claims.
* * * * *